BASIC KNOWLEDGE

ELECTRONICS

URA

www.hella.com/soe-electronics
02 | 03 CONTENTS

CONTENTS

SENSOR
INTELLIGENT BATTERY SENSOR 04
OIL LEVEL SENSORS PULS 16
RAIN/LIGHT SENSOR 24
ANGULAR POSITION SENSOR 36
PEDAL SENSORS 44

REMOTE CONTROL SYSTEM

REMOTE KEY 52

ACTUATOR
MICRO-ACTUATOR64
LINEAR ACTUATOR 72
INFORMATIVE, COMPACT, INTERACTIVE HIGH-FORCE ACTUATOR 80
SMART UNIVERSAL ROTARY ACTUATOR 86
The purpose of our online information is to give you more ways to efficiently and conveniently
identify the latest HELLA products and obtain important information about them. No matter what
you are looking for, we are certain to have the right part in our range:
SWITCH
➔➔ Product information
➔➔ Product videos ROCKER SWITCH 94
➔➔ Animations
www.hella.com/soe-electronics

➔➔ Configuration tools for many applications

➔➔ Online catalogs

You will find everything you need to know about our electronics portfolio here.
www.hella.com/soe-electronics
04 | 05 INTELLIGENT BATTERY SENSOR

SENSOR
INTELLIGENT BATTERY SENSOR

The intelligent battery sensor (IBS) measures

the battery voltage, current and temperature
parameters reliably and accurately. Information
on the state of charge, battery aging and the
forecast starting ability of the battery is calculated
based on these measured values. The IBS is
available for 12-volt and 24-volt vehicle
electrical systems.
06 | 07 INTELLIGENT BATTERY SENSOR

FAQ

01 WHICH INTELLIGENT
BATTERY SENSOR CAN BE
USED FOR WHICH VEHICLE?
The 12 V IBS can be used in all vehicles
equipped with a 12 V battery. This
applies above all to passenger cars, motor homes/caravans,
agricultural machinery, small construction vehicles, quads,
diesel forklifts, etc.
The 24 V IBS, on the other hand, is suitable for vehicles
equipped with two series-connected 12 V batteries (i.e. 24 V
vehicle electrical system), for example city buses/coaches,
large construction vehicles, trucks, etc.

03 WHAT CAN THE INTELLIGENT

BATTERY SENSOR BE USED
FOR?
The IBS directly records the measured
variables of current, voltage and

02
WHAT ADDED VALUE DOES
THE SYSTEM OFFER?
In the simplest application, the IBS
can be used for battery monitoring.
Here, for example, a warning can be
issued if the battery is in a critical state of charge. The limit
value for this can be freely defined by the user.
The IBS can also be used to regulate start-stop systems: for
example, the automatic start-stop function can be switched
off in the event of a low residual charge in order to conserve
battery resources, thus enabling further starting processes.
battery temperature. These values are used to calculate the
state of charge (SoC), state of health (SoH) and a forecast of
the starting ability (SoF – state of function). This information
can then be issued via a control panel or the on-board
computer. In addition, the remaining battery life (time to
complete charge or discharge) can be determined in this
manner.
If the IBS is used in conjunction with telematics systems, the
entire fleet can be monitored in terms of battery condition and
starting ability.
05
WHAT NEEDS TO BE
CONSIDERED DURING
MOUNTING?
When mounting, it is imperative to
ensure that the sensor is first
connected to the ground cable, and only then attached to the
battery. This prevents the sensor from accidentally coming
loose from the battery pole. In the respective application, the
battery cable must also be secured after a length of approx.
15 cm in order to absorb the torque generated at the sensor.
06
HOW DOES THE
COMMUNICATION BETWEEN
SENSOR AND VEHICLE
WORK?
The IBS normally communicates with
the control unit via a LIN (Local Interconnect Network)
interface. All output values are available directly on the LIN
bus and do not still have to be calculated by the control unit
first. However, a LIN-based control unit is required for this.
As an alternative, a connection to a CAN bus is also possible,
provided a CAN-based control unit is to be used. Various

04
The state of health forecast also enables the user to replace gateway modules are available on the independent
the battery in good time when it has reached a critical aftermarket for this purpose.
capacity. In this way, failures can be avoided preventively.
HOW IS THE INTELLIGENT
BATTERY SENSOR MOUNTED/
FASTENED?
The IBS is attached directly to the
negative pole of the battery using the
battery terminal. The ground cable can be conveniently
attached to the ground bolt with a cable lug or the separately
available battery pole adapter.
08 | 09 INTELLIGENT BATTERY SENSOR
FAQ
07 HOW DOES THE SENSOR
HAVE TO BE CONFIGURED?
Prior to using the sensor, the battery
parameters "nominal capacity" (C20)
and the battery characteristic curve
(OCV curve) have to be programmed. The OCV is the "Open
Circuit Voltage", i.e. the battery voltage in idle mode. The
battery parameters can either be specified by the battery
manufacturer or determined by HELLA. Accordingly, the
sensor can be calibrated either by HELLA or by the customer
during final assembly.
The measurement of voltage and current as well as the
starting ability forecast are also possible independently
of a calibration.
08
HOW DOES THE INTELLIGENT
BATTERY SENSOR WORK/
HOW ARE THE MEASURED
VALUES RECORDED?
Current is measured in the IBS via the
shunt or measuring resistor. Here, the voltage drop between
two points, which is proportional to the current, is measured.
The voltage is measured using the supply voltage as a
reference. This is possible because the sensor receives a
steady positive from the battery, and the voltage is both the
supply voltage and the measured voltage.
The temperature is determined by the temperature sensor
integrated in the electronics.
All other output values are calculated algorithmically from
these three measured values by the software (BMS – battery
monitoring software) via a controller specially developed for
this purpose.
09 HOW DOES THE IBS
CALCULATE THE ACTUAL
STATE OF CHARGE (SOC)?
In active phases, i.e. during battery
charging or discharging, the charge
condition is determined based on the amp-hour counter.
During idle periods, e.g. when the vehicle is parked, the
sensor automatically recalibrates itself based on the
measured open-circuit voltage. The current value may not
exceed a predetermined value. Furthermore, determination of
the state of charge is also temperature-compensated.
10
HOW SHOULD BATTERY
AGEING (SOH) BE
INTERPRETED?
The information on the battery
state of health (SoH) provides an
early warning function: As soon as the SoH value remains low
over a long period of time due to the state of aging of the
battery and is no longer normalised even during longer
charging phases, this is a clear warning that the battery has
lost capacity and is to be replaced.
11 HOW DOES THE 12 V IBS
DIFFER FROM THE 24 V IBS?
Compared to the 12 V sensor, the 24 V
sensor uses a shunt with a lower
resistance. This enables higher
robustness against starter currents. Furthermore, the two
sensors differ in the connectors used: 12 V IBS has a two-pole
connector, while the 24 V IBS has a three-pole connector due
to the insulated monitoring of the two series-connected
batteries. Through the separate interfaces to +12 V and +24V,
unevenly charged batteries can be detected.
See question 1 on page 06 for information on the fields of
application of the two sensor versions.
13
HOW DOES THE IBS BEHAVE
WHEN REPLACING A
BATTERY?
In the event of a battery replacement,
a POR (Power on Reset) is performed.
This causes the history and information on ampere hours,
12
cycles, aging, etc. to be reset. Important: The battery
parameters previously set remain. It is therefore imperative
HOW DOES TEMPERATURE that only batteries of the same type and capacity are used,
COMPENSATION WORK WITH otherwise the accuracy of the battery state recognition cannot
THE INTELLIGENT BATTERY be assured.
SENSOR? WHY IS IT
IMPORTANT?
The temperature is measured based on a temperature sensor
integrated in the IBS. An additional software algorithm
references to the actual core temperature of the battery from
the measured value.
This is important because the battery issues a lower open-
circuit voltage at lower temperatures in idle mode or longer
standstill times. In order to calculate the charge condition with
a higher level of accuracy, temperature compensation is
carried out.
10 | 11 INTELLIGENT BATTERY SENSOR

FAQ

14 WHAT IS THE ACCURACY OF

THE INFORMATION ON THE
STATE OF CHARGE (SOC)?
The accuracy of the state of charge
(SoC) depends on various influencing
factors: on the one hand, whether the transmitted battery
parameters match the battery actually connected, and on the
other hand, whether regular recalibration can be performed
due to the usage profile of the respective vehicle.
As a result, it is only possible to make a statement on the
charge condition under consideration of a certain tolerance.

16 WHAT EXACTLY DOES THE

SOF – STATE OF FUNCTION
– SPECIFY?
The algorithm for the state of function

15
(SoF) provides a forecast of the
starting ability of the engine. In the event of an engine start,
FOR WHICH BATTERY TYPES the voltage drops briefly due to the starter current. This is
CAN THE INTELLIGENT registered by the IBS (start detection) and a software
BATTERY SENSOR BE USED? algorithm calculates the forecast future voltage drop when the
The IBS is ideally suited for all starter is started on this basis. If this falls below a critical
conventional lead-acid batteries threshold, there are several options for intervention: either by
(flooded, EFB, AGM and gel batteries). sending a warning message to the driver, automatically
The IBS can also be used for 12 V lithium ion batteries, starting the engine, or suspending the start/stop automatic
although only for monitoring the current, voltage, and system for a certain period of time.
temperature. In this case, it is unfortunately not possible to
determine the charge condition – this must be determined by
other means.
12 | 13 INTELLIGENT BATTERY SENSOR

INTELLIGENT BATTERY
SENSOR 12 V
APPLICATION EXAMPLE: CARAVANS
AND MOTOR HOMES

INTELLIGENT BATTERY SENSOR

THE FACTS
Thanks to the seamless system integration into the on-board electronics network of
motor homes via the CI bus interface, the Intelligent Battery Sensor (IBS) enables
direct bidirectional communication with various peripheral devices such as LCD
control panels, smartphone applications, etc. Intelligent multiplexer systems (MUX)
enable the monitoring of several batteries in the vehicle.

CI BUS

230 V OPTIMUM CHARGING VOLTAGE

BASED ON IBS MEASURED VALUES

CI-BUS compatible Battery with HELLA IBS LCD control panel Motor home smartphone application
230 V rapid charger of the latest generation with battery monitoring function
14 | 15 INTELLIGENT BATTERY SENSOR

INTELLIGENT BATTERY
SENSOR 24 V
APPLICATION EXAMPLE: TRUCK

INTELLIGENT BATTERY SENSOR

THE FACTS
Based on the battery temperature and battery status (SoC), the Intelligent Battery
Sensor (IBS) provides reliable battery charge management and advanced alternator
control. This enables the charging behaviour to be controlled; for example, by
increasing the charging voltage at low temperatures. Furthermore, parameters such
as battery charge, function and status are continuously recorded and can be issued
to the driver and peripheral devices. Intelligent charging management (e.g. energy
storage during braking) enables a regenerative charging strategy with fuel
consumption optimisation to be pursued.

© Martin Vonk

Connected IBS 24 V Mounting the IBS Display of battery charge, function and status
in the cockpit of the Ford Otosan Cargo
16 | 17 OIL LEVEL SENSOR PULS

SENSOR
OIL LEVEL SENSOR PULS

Oil sensors in the vehicle ensure that the engine

cannot run with too little oil without this being
noticed. The sensor monitors the oil level
continuously during the entire engine operation,
thus preventing the oil level from falling below
its minimum in engine operation, which in turn
means that the oil film is never broken (which
would lead to engine damage). Marginal
influences such as an inclined position of the
vehicle and lateral and longitudinal acceleration
are compensated by an averaging out in the
vehicle's electronic control unit.
18 | 19 OIL LEVEL SENSOR PULS

FAQ

01 WHAT IS THE PULS OIL

LEVEL SENSOR USED FOR?
The PULS (Packaged Ultrasonic Level
Sensor) oil level sensor is used to
measure the oil level and the oil
Oil pan

Oil level and temperature

Engine control
unit
(ECU)

Low oil
Dashboard

04 WHICH PULS VARIANT IS

THE RIGHT ONE FOR MY
APPLICATION?
The PULS exists in different "damping
cap" lengths. The oil level is
Central position
in the oil pan

temperature in the oil pan. In contrast to conventional warning

measured within these damping caps. The selection of the
systems, the measurements can be taken both in the static correct sensor and the required damping caps as well as their Front of oil pan Back of oil pan
Motor speed
range (with the engine switched off) and in the dynamic range ideal positioning in the oil pan depend mainly on the factors
(with the engine running). package space, static and dynamic oil minimum and
maximum levels in the engine as well as the desired
application (e.g. overfill recognition, dynamic measurement,

03
HOW DOES THE
PULS WORK?
The PULS operates based on an
ultrasonic measuring principle.
An ultrasonic transmitter is integrated
in the electronics of the sensor, which is also known as multi-
06
etc.). HELLA will be happy to support you in selecting the
PULS that is best suited to your individual application
requirements.
HOW IS THE
PULS MOUNTED?
Usually, the PULS is mounted in the
oil pan from below using screws.
A sealing ring integrated in the flange
prevents the oil from leaking. To increase the measuring

02
chip module (MCM). This sends ultrasonic waves to the oil range, the sensor can also be mounted on a recess of the oil
surface, which are reflected back onto the multi-chip module. pan. It is also possible to install the PULS inside the oil pan.
WHAT ARE THE ADVANTAGES The MCM evaluates how long the ultrasound signal requires However, this means that the customer has to install a
OF THE PULS?

The PULS can help to prevent the
vehicle engine from working
unnoticed with too little oil, which can
lead to expensive engine damage. The PULS can also detect
overfilling. The advantage is that the oil level can be called up
05
for the outward and return journey and calculates the oil level special, media resistant cable leading out of the oil.
from this via an integrated algorithm. The temperature
measurement is based on a temperature sensor integrated in
WHAT NEEDS TO BE
the MCM. CONSIDERED FOR DYNAMIC
MEASUREMENT?
In the event of a dynamic

at any time by the user on the display/on-board computer. measurement, i.e. during engine
The conventional measurement via the mechanical dipstick in operation, an evaluation algorithm must be developed in the
the engine compartment is therefore no longer necessary control unit that compensates the effects of driving – e.g. oil
– a clean, convenient solution. Therefore, in its role as an temperature, engine speed, lateral and longitudinal
"electronic dipstick", the PULS can either replace the acceleration, etc. However, certain marginal impacts, – such
mechanical dipstick entirely, or serve as an additional as the tilt of the vehicle – also have to be recorded for static
measuring aid. measurement with suitable sensors and taken into
consideration in the assessment algorithm.
The evaluation itself is based on an averaging in the electronic
control unit over a defined time.
07
WHAT IS THE BEST WAY OF
MOUNTING THE PULS IN THE
OIL PAN?
The influence on the measurement
results by interfering factors during
travel is lowest in the middle of the oil pan. It is therefore
advisable to mount the PULS as centrally as possible in the oil
pan. However, the sensor should not be attached in the
immediate vicinity of the oil pump or the oil return line. The
specified distances to the movable mounting parts (shafts,
connecting rods, etc.) need to be assured. Furthermore,
protecting the PULS from splashes from above with a suitable
baffle plate (oil separator) is recommended.
20 | 21 OIL LEVEL SENSOR PULS

FAQ

09 WHAT NEEDS TO BE
CONSIDERED REGARDING
OPERATION AT LOW OIL
TEMPERATURES?
At low temperatures (below 0°C),
the oil has high attenuation and becomes increasingly viscous.
This means that the ultrasonic waves can only move through
the oil with difficulty and therefore not enough ultrasonic
energy is reflected back to the multi-chip module (MCM). We
therefore recommend limiting the oil level measurement to
temperatures above 0°C. At a temperature of -10°C, the
measurement function is turned off completely by the
software. The evaluation algorithm in the electronic control
11 CAN I ALSO USE THE
SENSOR FOR OTHER FLUIDS
(E.G. HYDRAULIC OIL)?
This depends on the individual case
and therefore requires prior
examination and approval by HELLA. In general, the design of
the sensor alone dictates exclusive use with engine oil, and
this is also recommended. With certain variants of the PULS,
measurements are taken inside the sensor. There is an
increased risk of corrosion for special media with aggressive
chemical components (such as hydraulic oil), foreign matter
(such as transmission oils) or a high water percentage (such
as certain propellants).

08
unit should take this into consideration and ignore the sensor
signals during this period of time. As soon as the oil has
WHY IS IT IMPORTANT TO reached its operating temperature, for example due to an
PROTECT THE PULS FROM engine start, static/dynamic measurements can again be
OIL SPLASHES FROM ABOVE? performed as usual.
When splashes occur, it is possible
that oil and air bubbles enter into the
measurement channel from the top through the cap and
disrupt measurements in such a way that plausible
measurement is no longer possible. In the event of doubt, the

12
assembly situation should be provided to HELLA for
verification.
WHAT INFORMATION CAN
THE DRIVER BE PROVIDED

10
WHICH ENGINE OILS IS THE
SENSOR COMPATIBLE WITH?
The PULS is compatible with all
commercially available engine oils.
The approved viscosities are defined
in the sensor specification. HELLA uses Castrol 5W30 as a
reference oil for various tests on the product.
WITH?
This depends mainly on the
evaluation algorithm, the function
required by the customer and the installation situation.
Possible useful information for the driver includes: A warning
about the oil minimum (when a threshold is violated),
a warning about overfilling, the visual display of the oil level
(in the form of a bar/percentage/stage or traffic light),
through to the calculation of the amount of oil to be refilled.
Further individual customer requirements can be realised in
consultation with HELLA.
22 | 23 OIL LEVEL SENSOR PULS

OIL LEVEL SENSOR PULS

APPLICATION EXAMPLE: AGRICULTURE

OIL LEVEL SENSOR PULS

THE FACTS
The PULS (Packaged Ultrasonic Level Sensor) determines the dynamic and static oil
level and also monitors the oil temperature.
If the oil reaches too low a level or a critical temperature, an appropriate warning
signal can be transmitted to the driver in order to initiate prompt actions.

Possible installation position of the oil level sensor in the oil Oil level sensor
pan of a diesel engine
24 | 25 RAIN/LIGHT SENSOR

SENSOR
RAIN/LIGHT SENSOR

Combination sensors such as the rain/light sensor

(RLS) are being used more and more frequently
in modern vehicles – because they enable the
convenient automatic switching of various vehicle
functions such as windshield wipers, low beam
etc. The RLS from HELLA is the first device in
which up to five functions can be integrated into
just one sensor, and in any combination.
Customer-specific software solutions and
programming ensure that the functional
sequences are specially adapted to the
respective vehicle.
26 | 27 RAIN/LIGHT SENSOR

FAQ

03 WHAT REQUIREMENTS MUST

BE FULFILLED TO BE ABLE
TO USE THE RAIN-LIGHT
SENSOR?
The function of the rain/light sensor
05 WHAT HAPPENS IF MY
WINDSHIELD PARAMETERS
ARE DIFFERENT TO THE
REQUIREMENTS OF THE
RAIN/LIGHT SENSOR?
depends on the technical data of the windshield, among If the parameters are different, the rain/light sensor may not
other things. Here, the tilt of the windshield is crucial for the work at all or only work with limitations. If, for example, the
lighting function, while the windshield thickness is decisive for windshield tilt is outside of the tolerance range, the light
the rain function. Furthermore, the curvature radius and the switching function may work with a certain delay for special
transmission of the windshield play an important role for the situations – such as when entering a tunnel or for low sun in
rain/light sensor to function properly. the morning/evening.

01 WHAT IS THE RAIN/LIGHT

SENSOR USED FOR?
The rain sensor determines the
rain intensity and then, based on this,
02 HOW DOES THE RAIN/LIGHT
SENSOR WORK?
The rain sensor is based on an optical
measuring principle: The light from

controls the windshield wiper or
wiper motor such that the driver will hardly ever need to
intervene. The light sensor controls turning the low beam on
and off in special situations (e.g. when driving through a
tunnel, dusk/dawn). Furthermore, the light sensor can also be
used to regulate the light intensity of the instrument lighting
(on-board computer, terminal, switches, etc.) based on the
current lighting conditions. The available solar and humidity
sensor available as an option provides input information for
the climate control system.
the transmitter diode is reflected onto
the outside of the windshield, bundled via a lens, and
transmitted to the receiver diode. If there are water drops on
the outside of the windshield within the measuring range of
the sensor, part of the light in the area of the water drop is
"blocked". This reduces the irradiance detected by the
receiving diode. The change in irradiance is measured by the
evaluation electronics and appropriate instructions are issued
to the wiper electronics. The lighting function is also based on
an optical measuring principle. Two independent front and
ambient light diodes are used. This, for example, enables a
reliable differentiation between tunnels and bridges.
04
HOW CAN I DETERMINE
WHETHER MY WINDSHIELD
MEETS THE RAIN/LIGHT
SENSOR REQUIREMENTS?
Within a project, HELLA can provide a
section of windshield (10 cm x 10 cm) from the intended
installation position of the sensor for the purposes of
transmission measurement. Firstly, this ensures that the rain
sensor can automatically calibrate itself to the respective
windshield. Secondly, HELLA can give recommendations to
the manufacturer for certain configuration parameters.
Alternatively, the required data can be obtained from the
windshield manufacturer.
06
HOW DOES THE RAIN/LIGHT
SENSOR COMMUNICATE WITH
THE VEHICLE?
The rain/light sensor communicates
with the vehicle via the LIN interface.
The sensor sends the wiper or light switching requests
directly to the master control unit without requiring further
processing of the data by the vehicle first.
28 | 29 RAIN/LIGHT SENSOR
FAQ
07 WHAT ARE THE SPECIAL
FEATURES OF LIN
COMMUNICATION?
In contrast to other LIN sensors,
the rain/light sensor communicates
bi-directionally. This means that it not only provides the
vehicle with information on the current rain and light situation,
but also receives certain information from the vehicle
(chassis), e.g. the driving speed, wiper position, and outside
temperature.
Based on this information, the rain/light sensor then adjusts
its behaviour accordingly. The vehicle and sensor information
need to be transferred cyclically one after another.
08
WHAT NEEDS TO BE
CONSIDERED WHEN
SELECTING A SUITABLE
POSITION FOR ATTACHING
THE RAIN SENSOR?
The rain sensor must be attached in an area of the windshield
where at least one wiper wipes across it. Mounting the sensor
in the immediate vicinity of peripheral components that are in
the sensing area of the light diodes should be avoided. HELLA
should be consulted in the event of doubt. Due to the
orientation of the sensor optics, the sensor must be mounted
at an angle of 198° to the Y-axis.
09
HOW IS THE SENSOR
CONFIGURED?
The sensor is configured during initial
commissioning. First, 3 ignition cycles
need to be performed in order for the
sensor to automatically calibrate to the windshield.
Then, a configuration message needs to be sent to the sensor,
the content of which (e.g the windshield type) was already
agreed upon with HELLA.
10
WHY IS THE WIPER POSITION
SO IMPORTANT?
The wiper position is one of the main
input variables for rain detection.
The rain sensor has to be informed
that the wiper has left the parked position (resting position),
and as soon as it returns to this position. This is important
since the water transferred by the wiper itself to the sensor
should not be detected as "real" rain. Correspondingly, the rain
sensor turns off rain detection as soon as it is "washed over"
by the wiper. This prevents undesired wiping and ensures
homogeneous wiping.
11 HOW IS THE SENSOR
ATTACHED TO THE
WINDSHIELD?
The sensor is attached to the
windshield with a fastening element
(bracket) designed especially for this purpose. The can either
be provided by HELLA or defined by the vehicle manufacturer.
The tension spring of the rain sensor and the snap-fixing of
the bracket generate the necessary contact pressure on the
windshield. The sensor is coupled to the windshield via a
special silicone pad that is part of the rain sensor.
The bracket is usually mounted by the windshield
manufacturer. The windshield manufacturer also selects a
13
suitable bonding method for fixing. It should be noted here
that HELLA has merely developed a standard bracket, but lays
down no specifications for the bonding process.
WHAT NEEDS TO BE
CONSIDERED WHEN USING
HEATED WINDSHIELDS?
HELLA has ensured compatibility in a
customer application with heated
windshields in the form of heating wires. The function of the
rain sensor remains unaffected as long as the heating wires
do not exceed a certain density. Special designs require prior
agreement with HELLA.
12
WHAT NEEDS TO BE
CONSIDERED WHEN USING
IR-REFLECTING
PROTECTIVE FOIL?
In general, the rain/light sensor
cannot be used with an IR-reflecting foil, because the light of
the rain running down the windshield no longer reaches the
outside of the windshield and therefore useful measurements
are no longer possible. If IR-reflecting intermediate layers are
used, the foil therefore needs to be cut out correspondingly in
the area of the rain sensor.
30 | 31 RAIN/LIGHT SENSOR

FAQ

15 WHAT DO I NEED TO
CONSIDER IF I WANT TO USE
THE RAIN/LIGHT SENSOR IN
A DIFFERENT VEHICLE?
You need to check how far the
17 HOW DOES THE RAIN
SENSOR BEHAVE WITH
SNOW AND ICE?
The rain sensor cannot differentiate
snow from rain. Snow flakes are
baseline conditions (windshield, LIN communication with the interpreted as large drops of water. Correspondingly,
control unit, wiper arrangement) differ from the original the behaviour of the rain sensor is controlled according to the
vehicle. You may have to adjust certain software parameters, intensity of the snowfall. However, the sensor can differentiate
which in turn may require a new variant. Agreement with ice from rain when the outside temperature is sent to the rain
HELLA is required in any case. sensor. In this case, the wiper requests will not be sent in
order to prevent possible damage to the wiper blade by
the ice.

14 WHAT OTHER ADJUSTMENTS

HAVE TO BE MADE TO THE
VEHICLE?
There also needs to be the ability
within the vehicle of activating the

18
rain/light sensor. This can, for example, be a light switch with

16
an "automatic" position, or an extended steering column
switch for turning the rain sensor on/off. In addition, a
CAN I ATTACH AND REMOVE
possibility to regulate the sensitivity of the rain sensor is
HOW DOES THE RAIN A RAIN SENSOR MORE THAN
recommended, because the same rain situation can be SENSOR BEHAVE WHEN THE ONCE?
perceived differently by different drivers. WINDSHIELD IS SOILED WITH This is generally not recommended,
DIRT, ETC.? because the coupling medium wears
In the case of permanent mud/dirt/ off when you take it off and air bubbles can form during the
dust/salt on the windshield, the rain sensor no longer sends subsequent reattachment.
any wipe requests to the control unit in order to prevent the For certain variants, however, the optical element including
dirt being spread over the windshield. It increases its tolerance coupling medium is available as a separate spare part.
range internally to allow more (rain) water so that the wiper In the event of service, therefore, the entire sensor does not
can remove the dirt from the windshield in the best way have to be replaced.
possible.
32 | 33 RAIN/LIGHT SENSOR

RAIN/LIGHT SENSOR
APPLICATION EXAMPLE: PASSENGER VEHICLE

RAIN/LIGHT SENSOR
THE FACTS
The rain/light sensor (RLS) from HELLA can be individually adapted for a large
number of vehicle models. The sensor is usually integrated into the base of the
vehicle interior mirror in passenger cars. Sensor parameters and the sensor
sensitivity can be adapted to the vehicle-specific windshield.
The LIN interface can be customized according to the vehicle architecture.

Integration in the base of the interior rearview mirror Vehicle-specific holder Rain/light sensor
34 | 35 RAIN/LIGHT SENSOR

RAIN/LIGHT SENSOR
APPLICATION EXAMPLE: VDL BUS

RAIN/LIGHT SENSOR
THE FACTS
Bus drivers bear a great deal of responsibility for their passengers and must
therefore always concentrate optimally on traffic. The automatic wiper switching of
the HELLA rain/light sensor (RLS) relieves the driver of the need to operate the
corresponding levers – increasing safety. The integrated light sensor controls the
switching on and off of the dipped beam in different ambient light conditions as well
as during tunnel or garage driving. The HELLA RLS thus offers both an increase in
safety and convenience.

Rain/light sensor on the windshield of a VDL bus Rain/light sensor Fastening element
36 | 37 ANGULAR POSITION SENSOR

SENSOR
ANGULAR POSITION SENSOR

HELLA CIPOS® Contactless Inductive Position

Sensors (angular position sensors) reliably
measure angles in numerous automotive
applications.
The angle is determined without contact via
induction and is therefore completely wear-free
– for high measuring accuracy over the entire
service life. Special double sensors enable failure
detection through redundant functions and offer
increased safety for the complete system.
38 | 39 ANGULAR POSITION SENSOR

FAQ

01 WHERE CAN I FIND A

ANGULAR POSITION SENSOR
IN THE VEHICLE?
Angular position sensors can be
installed in vehicles in a variety
03 WHAT ARE THE ADVANTAGES
OF CIPOS® TECHNOLOGY?
CIPOS® stands for Contactless
Inductive Position Sensor. The special
feature of the CIPOS® technology is
of ways. Potential application examples include: the inductive angle determination via a contact-free and thus
➔➔ Accelerator pedal position for recording the torque wear-free process. The insensitivity to magnetic fields and
requirement for the engine control system high level of temperature stability in particular are the
➔➔ Throttle valve position for throttle valve control characteristic qualities of this technology. A high degree of
➔➔ Steering angle precision is thus guaranteed throughout the entire service life Housing version A Housing version C
➔➔ Vehicle level measurement of the sensor.
➔➔ Position measurements of adjustable elements
Housing version B

02 HOW DOES THE ANGULAR

POSITION SENSOR WORK?
The lever arm torque is measured
05 WHAT IS THE DIFFERENCE
BETWEEN SINGLE
SENSORS AND DUAL
SENSORS?
The angular position sensors are
04 WHAT HAS TO BE
CONSIDERED WITH REGARD
TO THE CHARACTERISTIC
CURVES?
The characteristic curve of the
above the rotor via an induction available as single sensors and as double sensors, each in angular position sensor repeats every 120°. This means that it
process. The position of the rotor is different versions. In contrast to single sensors, double cannot only be mounted in the position shown, but can also be
calculated precisely via an ASIC (Application Specific sensors offer redundant angle measurement and are offset by a multiple of 120°, up to a maximum of 360°.
Integrated Circuit). Various mounting positions are possible particularly suitable for safety-critical applications due to the The connected system remains unaffected. The measuring
via the repetitive characteristic curve of the output signal path failure detection made possible by this system. angle range varies depending on the sensor. If it is exceeded
(depending on used sensor structure). It increases the flexible specified value, the output signal remains limited to the
sensor application options. measuring range final value. In the event of a further violation,
the next section of the characteristic curve is applied.

06
The resulting measuring ranges and zero positions are shown
in the graphical representation.
IN WHICH HOUSING DESIGNS
Rotor IS THE ANGULAR POSITION
SENSOR AVAILABLE?
Stator Electronics
The angular position sensors are
Induction available in three different housing
designs – as single sensors, single sensors in a compact
design and as double sensors. These different versions enable
a multitude of different application areas.

Excitation coil
Receiver coil
40 | 41 RAIN/LIGHT SENSOR

FAQ

08 WHAT IS AN ANALOG
OUTPUT?
With analog output and with a supply
voltage of 5 V DC, the measured
angle is reflected through the ratio of
10 WHAT CIRCUITRY MUST BE
USED FOR A RATIOMETRIC
OR FIXED VOLTAGE OUTPUT?
If the ratiometric (10% to 90%) or
U

HSD high-side driver

Battery

ECU
Sensor Supply

the output voltage (Uout) to the operating voltage (US) (as a
ratiometric to the supply voltage). This signal is issued via a
high side driver (HSD). At a supply voltage of 9 V to 32 V
(multi-voltage), the measured angle is reflected through a
voltage of 0.5 V to 4.5 V.
U the high-side driver (HSD) is used as an analog output, the output
U pull-up
fixed voltage output (0.5 – 4.5 V) is
connected, an external pull-down resistor is required. For a 5 Sensor > 2,5 kΩ
V supply, e.g. 2.7 kΩ to 10 kΩ must be selected. The maximum < 25 nF
output current of the analog output should not exceed 2 mA.
Because the high-side driver (HSD) is used as an analog
output, the output voltage is set relative to the supply voltage.
CIRCUITRY FOR RATIOMETRIC (10% TO 90%)
OR FIXED VOLTAGE OUTPUT (0.5 TO 4.5 V)
An external pull-down resistor is required for this variant.
For a 5 V supply, e.g. 2.7 kΩ to 10 kΩ must be selected. The maximum
output current of the analog output should not exceed 2 mA. Because
voltage is set relative to the supply voltage.

variabel
zum Winkel

Tlow Thigh

07 WHAT TYPES OF
CONNECTING ELEMENTS ARE
AVAILABLE?
There are three different types of
0V
T period

PWM OUTPUT (DIGITAL)

t

11 HOW DOES THE

CIRCUITRY WORK FOR THE
PWM OUTPUT ON THE
U
Battery

Sensor Supply
ECU
< 25V

connecting elements available:
a) Connecting element with two ball head screws
b) Connecting element with two ball head screws,
one of which is turned by 180°
c) Connecting element with cover cap and
one ball head screw
These are available in different lengths and thus enable the
flexible integration of the angular position sensors into the
respective application.
09
WHAT IS A PWM
OUTPUT?
When using the PWM signal, the
angular position of the angular
position sensor results from the ratio
between the low time (Tlow) of the PWM signal and the period
time (Tperiod). The absolute time of the high or low level is not a
measure of the angle. The PWM signal is output via a low side
driver (LSD). Naturally, it is also possible to evaluate the ratio
of high time (Thigh) to period time (Tperiod). This results in a
characteristic curve that is inverse to the analog signal.
LOW-SIDE DRIVER (LSD)? Peak
LSD low-side driver
The maximum current through the
pull-up resistor is specified in the external ECU, because an Sensor
LSD is used as PWM output. In order to keep the output
current as low as possible, HELLA recommends the use of
10 k¹. The pull-up resistor also limits the sensor output
current, which should not exceed 5 mA. The voltage and
transients at the pull-up resistor must not exceed 25 V.
CIRCUITRY FOR THE PWM OUTPUT ON THE
LOW-SIDE DRIVER (LSD)
The maximum current through the pull-up resistor is specified in the
external ECU, because an LSD is used as PWM output. In order to keep
the output current as low as possible, HELLA recommends the use of
10 kΩ. The pull-up resistor also limits the sensor output current, which
should not exceed 5 mA. The voltage and transients at the pull-up
resistor must not exceed 25 V.
42 | 43 ANGULAR POSITION SENSOR

ANGULAR POSITION SENSOR

APPLICATION EXAMPLE: CLAAS COMBINE HARVESTER

ANGULAR POSITION SENSOR

THE FACTS
More than 400 million angular position sensors have been produced since 1999. The
are characterized by temperature robustness, high accuracy and measuring speed.
HELLA’s CIPOS® technology (contactless inductive position sensor) is an essential
part of precise position measurement. The vehicle level sensor is a compact rotary
encoder solution assembled on the vehicle suspension, and supports automatic
headlamp leveling and active chassis control. The angular position sensor can also
be used in the brake pedal, clutch pedal or another application that can be coupled
by a linkage.

Angular position sensor on the boom of a combine harvester Angular position sensor
44 | 45 PEDAL SENSORS

SENSOR
PEDAL SENSORS

The pedal sensor is part of the drive train of the

vehicle and serves to increase or decrease the
speed by measuring the pedal position via the
engine electronics.
The HELLA CIPOS® technology is used for position
measurement, which offers a highly accurate and
contactless measuring principle. HELLA was the
first component manufacturer to develop and
produce electronic sensors for pedal sensors and
has been the market leader in this field for many
years.
46 | 47 PEDAL SENSORS

FAQ

05 06
WHAT IS THE CIRCUITRY AND PIN
WHAT IS THE MEASURING
ASSIGNMENT?
PRINCIPLE USED AND HOW
HIGH IS THE MEASURING
SUSPENDED ACCELERATOR PEDAL
ACCURACY?
The HELLA CIPOS® technology is Pin 1: 5 V supply: sensor 1
used as the measuring principle. This offers the highest level Pin 2: Analog signal: sensor 1
of measuring accuracy thanks to specially developed and Pin 3: Ground: sensor 1
patented measuring sensors. The sensors are largely Pin 4: Ground: sensor 2
unaffected by temperature fluctuations. The wear-free Pin 5: Analog signal: sensor 2
measuring principle also guarantees a particularly long Pin 6: 5 V supply: sensor 2
service life for accelerator pedals with small, frequently
recurring movements. Ausgang Fahrpedal
Pedal output ECU

1(VCC1) Vcc 1

01 03
6(VCC2) Vcc 2

2(OUT1)
WHAT TYPE OF PEDAL WHAT APPLICATIONS ARE C1 R1 R2 C2
Analog1
Analogue1

SENSORS DOES HELLA HELLA PEDAL SENSORS 3(GND1) AD

AD

OFFER? SUITABLE FOR? 5(OUT2)

Analog2
Analogue2
R4
C3 R3 C4
HELLA offers accelerator pedals for The HELLA accelerator pedals can be
4(GND2)
upright and suspended mounting. used in a wide variety of vehicles –
The HELLA sensor can also be used in fully electronic clutch from automotive applications, such as sports cars and electric
pedals. Customer-specific solutions can be offered on request. vehicles, to robust applications in agricultural vehicles and
Brake pedals are not offered because they are made of metal construction machinery.
and this is not one of HELLA's core competencies.
Pin 1: Ground: sensor 1
Pin 2: Logic earth: sensor 2
Pin 3: Supply 5 V: sensor 2

04
Pin 4: Analogue signal: sensor 1
Pin 5: Supply 5 V: Sensor 1
WHAT ARE THE Pin 6: Analogue signal: sensor 2
ADVANTAGES OF HELLA
PEDAL SENSORS?

02
Ausgang Fahrpedal
Pedal output ECU

The HELLA accelerator pedals have a 5(VCC1) Vcc 1

IS A TEACH-IN PROCESS slim design for use even in narrow 3(VCC2) Vcc 2
NECESSARY IN THE driver cabins. Even with frequently recurring small 4(OUT1)
Analog1
VEHICLE? movements, the HELLA accelerator pedals guarantee C1 R1 R2 C2
Analogue1

1(GND1) AD
No, a teach-in process in the vehicle extremely low mechanical wear due to the contactless AD
6(OUT2)
is not necessary. The sensor is measuring principle of the CIPOS® sensor used. This Analog2
Analogue2
R4
C3 R3 C4
calibrated at the end of the production process. In conjunction technology offers high measurement accuracy and high
2(GND2)
with CIPOS®, this guarantees high accuracy over the entire immunity to electrical and magnetic fields.
life cycle.
48 | 49 PEDAL SENSORS

FAQ

07 WHICH EMC CLASS

IS ACHIEVED?
Both the stationary and suspended
accelerator pedals reach
CISPR 25 Class 5.
08 DO THE HELLA
ACCELERATOR PEDALS MEET
THE "FUNCTIONAL SAFETY"
STANDARD?
Today, all HELLA accelerator pedals
are developed in accordance with the Functional Safety
Standard. From both a mechanical and electronic point of
view, the pedals offer a high level of safety. Firstly, the spring
package – through which the actuation force is generated – is
made up of two springs, each of which enable safe return

09
separately. Secondly, the accelerator pedal generates two
output signals which are electrically isolated from each other.
WHAT ARE THE OUTPUT
SIGNALS AND CAN THEY BE
ADJUSTED?
All HELLA pedal sensors generate
two analog output signals. Channel 1
increases with pedal actuation to approximately the supply

10
voltage.
Channel 2 has in each case half the value of channel 1. This
behaviour is referred to as a "half scale" characteristic curve.
CAN I CUSTOMISE
Alternative characteristic curves can also be programmed THE PEDAL?
on request. Customer-specific adaptations, such
as a new pedal plate, up to a
completely individual pedal can be
requested from HELLA.

Electrical characteristics

Wide Open Throttle Signal for ECU

90 %

Area
of
APS
stopper

90 % 45 %

45 %
10 %
5 %

Pedal operation
50 | 51 PEDAL SENSORS

PEDAL SENSORS
APPLICATION EXAMPLE: AGRICULTURE

PEDAL SENSORS
THE FACTS
The HELLA pedal sensors are used as accelerator pedals for the acceleration of
vehicles. They are particularly suitable for robust applications and can be used, for
example, in agricultural vehicles. The compact design enables installation even in
narrow driver cabs.

Suspended accelerator pedals in a tractor Suspended accelerator pedal

52 | 53 REMOTE KEY

REMOTE CONTROL SYSTEM

REMOTE KEY

The remote control system has been specially

developed for use in tough operating conditions
(agricultural and construction machinery, trucks).
The system enables the vehicle operator to
comfortably unlock the cab door. The remote
control can be equipped with one or two buttons,
depending on the customer’s requirements. The
design can be customised on request, e.g. to
incorporate customer-specific emblems.
54 | 55 REMOTE KEY

FAQ

03 WHICH PARTS ARE INCLUDED

IN THE SCOPE OF DELIVERY?
The scope of delivery includes two
remote controls (standard with two
buttons: button 1: lock symbol, button
2: light symbol) and a remote receiver with four outputs.
The remote receivers are programmed for the receiver during
production at the plant. The set also includes two dummy
plugs for use as hand-held transmitters without manual
locking, i.e. without a key bit.

05 WHAT DO I NEED TO
CONSIDER WHEN I WANT TO
USE THE KEY WITH LOCKING
FUNCTION (WITH A KEY BIT)?
Due to the receptacle construction,

01
WHAT CAN THE REMOTE KEY
BE USED FOR? WHAT ARE
THE TYPICAL APPLICATIONS?
Typical remote key applications
include the control of the central
locking system, turning on the interior and/or exterior lighting
of the vehicle (coming-home function), turning on the front
lighting and turning different operating elements on/off. As an
option, the remote key offers the possibility of implementing
an electronic immobiliser with control of the access function
or release of the starting process.
02
HOW DOES THE REMOTE
CONTROL WORK?
When you press a button, a radio
telegram is sent which is read by the
receiver and the corresponding output
is activated. The transponder electronics are responsible for
the immobiliser function. This is decoupled from the use as a
remote key and functions autonomously.
04
the key bit must have a thickness of 1.8 mm and have exactly
the contour specified in the dimensioned sketch as the
WHAT INDIVIDUALISATION connection to the remote control transmitter unit. The key bit
OPTIONS ARE AVAILABLE? and remote control transmitter must be assembled by the
A PU emblem (PU = polyurethane) customer or supplier of the key bit.
can be bonded to the rear in
accordance with customer
specifications. In addition, the symbols can be changed
depending on requirements. However, a separate variant
must be created for this.
56 | 57 REMOTE KEY
FAQ
06
WHAT ADDITIONAL
COMPONENTS DO I NEED?
In the simplest model, you need a
commercially available automotive
relay (e.g. time relay) for the
implementation of the different lighting functions. This is
connected to the corresponding outputs of the remote receiver
and connected with the periphery. An electronic control unit is
recommended for the central locking system with an interface
to the electronic door locking system, e.g. to the actuator
motors (actuators). To use the immobiliser function,
a transponder must be housed in the remote control
transmitter housing. Commercially available electronic
immobilisers are based on an electric coil that is mounted on
the ignition lock and coupled with associated electronics that
regulate access control.
07 WHERE CAN I USE THE
REMOTE CONTROL
TRANSMITTER?
The remote control transmitter can be
used in all countries that use a radio
frequency of 433.42 MHz. This applies to all countries except
South Korea and Japan. The remote control is currently
approved for the European Union, North America, and India.
Other countries are possible by arrangement with HELLA.
08
WHAT DO I NEED TO
CONSIDER FOR THE
IMPLEMENTATION OF AN
IMMOBILISER FUNCTION
WITH THE REMOTE KEY?
A transponder can be inserted in the remote key during
production that is specified by the customer or the supplier of
the immobiliser. However, this transponder is neither specified
by HELLA nor will HELLA check its functionality. The "pairing"
with the immobiliser module therefore takes place either in
the final assembly by the customer or at the supplier of the
immobiliser.
09 WHAT ARE THE
REQUIREMENTS ON THE
TRANSPONDER?
Two types of transponders can be
used: The wedge design and the tube
design. The suitability of the transponder only depends on its
dimensions.
The size of the two listed types may therefore not be
exceeded. However, it is possible to test the usability of
11
transponders that deviate from the standard. However, only
passive transponders, i.e. without a connection to the
electrical supply of the remote control transmitter, are
WHAT IS TO BE CONSIDERED
permitted. WHEN CHANGING BATTERIES?
The battery condition cannot be called
up directly. As a precaution, the
battery should therefore be replaced
at cyclic service intervals. To do this, the top and bottom of the
key housing must be separated, the old battery removed from
the holder, and the new battery then inserted. The battery type
is CR 2032.
10
WHAT IS TO BE CONSIDERED
IF A KEY IS LOST?
If only one of the two keys supplied
is lost, an individual key can be
re-ordered and then programmed by
the customer. To do so, a special button combination has to be
entered. Up to 7 keys can be programmed for one control unit.
If both keys have been lost, the entire system including the
remote receiver must be replaced.
The procedure for reprogramming new keys to the
immobiliser is defined by the respective supplier.
58 | 59 REMOTE KEY
FAQ
12
WHAT IS THE RANGE OF
THE REMOTE CONTROL?
The range depends on many factors
and is affected by many external
circumstances, such as the weather,
the mounting location of the remote receiver and disruptions
to the radio signal due to interference with other radio
frequencies. Therefore, HELLA is not able to give precise
information on the range. On request, however, we can
provide you with application-specific average values.
13
WHAT NEEDS TO BE
CONSIDERED WHEN
MOUNTING THE REMOTE
RECEIVER?
The remote receiver has eyelets for
cable strap mounting and can therefore either be attached
directly to the body or to special equipment. It must be noted
that in order to ensure clean reception, attachment below
metallic bodies is to be avoided. For this reason, it is mounted
in the vehicle interior, e.g. underneath the dashboard.
14 WHICH VEHICLES CAN THE
REMOTE KEY BE USED WITH?
The remote key can be used with all
vehicles with a 12 V or 24 V vehicle
electrical system and therefore
enables wide coverage of almost all vehicle types. Possible
application cases are, for example, buses, trucks, cars,
tractors, agricultural/construction vehicles, municipal
vehicles, and forestry equipment.
16 IS IT POSSIBLE TO CHANGE
THE SYMBOLS?
The specified symbols (lock or bulb)
can be changed or individualised on
customer request. However, this
requires the production of an independent variant. The
symbols are worked into the tool as a raised contour, meaning
that the injection molding tool must be changed for different
symbols. HELLA will be happy to advise you on the
15
possibilities of individualisation.
WHAT ADVANTAGES
DOES THE SYSTEM OFFER TO
FLEET OPERATORS?
The remote key enables driver
authentication possible for fleet
management. This is performed via the transponder, on which
driver-specific information can be stored. This information can
be read out individually on the vehicle side. The system
therefore provides the option of assigning specific keys to
individual drivers and assigning permissions with appropriate
software tools.
60 | 61 REMOTE KEY

REMOTE KEY
APPLICATION EXAMPLE: AGRICULTURE

REMOTE KEY
THE FACTS
The remote key can be used in conjunction with an electronic immobiliser. The
electronic immobiliser can be used for all types of vehicles and is ideal for
commercial vehicles, as well as agricultural and construction vehicles. The vehicle
key/remote key can be used to perform authorisation recognition of the driver. With
the help of an integrated programmable transponder, the vehicle key can also serve
as a storage medium for various data such as service intervals, mileage, etc.
Communication between the immobiliser and the control unit can be via CAN bus.

AUTHENTICATION CAN-BUS / SAE J 1939

Remote key with programmable transponder Electronic immobiliser Engine control unit
62 | 63 REMOTE KEY

REMOTE KEY
APPLICATION EXAMPLE: CONSTRUCTION VEHICLE

REMOTE KEY
THE FACTS
Independently of a central locking system, the remote key can also be used just to
control the work lighting. In conjunction with additional components such as a time
relay, the vehicle can be located remotely in the dark, for example.
Button symbols and other functions for the remote key, such as controlling the
dimming function of work lights, can be realised on request.

CONTROL COMMAND: SWITCHING ON/OFF, CHANGING THE DIMMING LEVELS

Remote key Receiver control unit Ultra Beam LED Generation II

INSTRUCTION ON/OFF, DIM/BRIGHTEN

64 | 65 MICRO-ACTUATOR

ACTUATOR
MICRO-ACTUATOR

Micro-actuators are indispensable – and often

almost invisible – small electronic helpers in
almost every vehicle. They are characterised by
high performance and compact dimensions and
guarantee maximum flexibility with regard to
simple vehicle integration. The actuators are used
in a large number of locking and unlocking
applications and are also suitable for electric
vehicles, for example, as they comply with
explosion protection regulations.
66 | 67 MICRO-ACTUATOR

FAQ

03 WHAT FORCE OR TORQUE

DOES THE MICRO-ACTUATOR
PROVIDE?
The micro-actuator works without
force and is only suitable for locking
and unlocking applications.

04 HOW IS THE POLARITY OF

THE ELECTRIC MOTOR
REVERSED?
An H-bridge can be used to control 06 HOW IS THE MICRO-
ACTUATOR USED TO LOCK
AND UNLOCK CONNECTORS

01 02
the electric motor, which enables FOR CHARGING ELECTRIC
polarity reversal. VEHICLES?
WHAT AREAS OF HOW DOES THE MICRO- For this purpose, an adapter must be
APPLICATION CAN THE ACTUATOR WORK? used which is mounted on the actuator shaft instead of the
MICRO-ACTUATOR BE When a voltage is applied, the electric locking element. The adapter converts the rotatory motion of
USED FOR? motor integrated in the actuator the shaft into a linear motion so that a pin can be used to lock
Thanks to the space-saving design, moves the locking lever attached to and unlock the connector.
this actuator is particularly well suited to locking and the shaft. The micro-actuator can thus perform a rotatory
unlocking applications in which only minimal packaging space locking/unlocking movement. The position reached can be
is available. Examples include tank modules, service doors, displayed via an integrated micro-switch.

05
glove compartments and charging plug locking in the field of With the micro-actuator with soft-touch function, the switch
e-mobility. integrated in the actuator is actuated by pressing the button
and the actuator is electrically activated via a control unit.
WHAT IS THE FUNCTION OF
The actuator unlocks and after it is switched off, the locking THE EMERGENCY OPERATION
element returns to the locking position by means of the LEVER?
integrated return spring. In the event of a defect or malfunction
of the micro-actuator, it can be
mechanically unlocked via the
emergency actuation lever and a
cable pull.
68 | 69 MICRO-ACTUATOR

MICRO-ACTUATOR
APPLICATION EXAMPLE: E-MOBILITY

MICRO-ACTUATOR
THE FACTS
The HELLA micro-actuators (MA) enable reliable plug locking on the vehicle as well
as on the charging station during the charging of vehicles of various manufacturers.
The actuators are dust- and water-protected and, thanks to the explosion protection
certificate, particularly suitable for use in electric vehicles. The HELLA micro-
actuators are used in a variety of locking and unlocking applications – either
remotely controlled by the driver or by touching the tailgate cover. With up to
100,000 application cycles, the actuators have an extremely long service life.

© MENNEKES Elektrotechnik

Charging pistol fuse connector with the HELLA micro-actuator Safe charging process thanks to reliable Example of a wall charging station
connector locking
70 | 71 MICRO-ACTUATOR

MICRO-ACTUATOR
APPLICATION EXAMPLE: CARAVANS
AND MOTOR HOMES

MICRO-ACTUATOR
THE FACTS
Especially for caravans and motor homes, the HELLA micro-actuators offer a wide
range of application possibilities with regard to the closing functions – for example,
external flaps, roof hatches, windows and doors can be opened more easily using the
actuators. Due to its small dimensions, the micro-actuator can be easily integrated
into the vehicle design.

Versatile actuator
application in the caravan sector
72 | 73 LINEAR ACTUATOR

ACTUATOR
LINEAR ACTUATOR

Linear actuators are electromechanical drive

elements that convert the rotary motion of an
actuator motor into linear motion. In this way,
they provide an electric-motor-controlled return
or automatic spring return function. Mechanical
elements are use to connect the linear actuator to
the respective application.
74 | 75 LINEAR ACTUATOR

FAQ

01 WHAT APPLICATIONS CAN

THE LINEAR ACTUATOR BE
USED FOR?
The linear actuator can be used for
the electrical locking, unlocking, and
05 HOW IS THE POLARITY OF
THE ELECTRIC MOTOR
REVERSED?
An H-bridge can be used to control
the electric motor, which enables
pull-closing of locking and hatch systems in automotive and polarity reversal.
industrial applications. Examples of this include the electrical
locking and unlocking of a central locking system, the
electrical pull-closing or the electrical opening and closing of
any door (locking systems), flaps, skylights, seats, covers,
hoods, glove compartments. The linear actuator can also be
used to open and close flaps for seed dosing.

03 HOW DOES THE LINEAR

ACTUATOR WORK?
When a voltage is applied, the electric
motor integrated into the actuator
moves a spindle gear, which retracts or
06 HOW CAN THE LINEAR
ACTUATOR BE UNLOCKED IN
AN EMERGENCY?
Certain linear actuators with a
corresponding spindle pitch can be
08 HOW IS THE RETRACTED/
EXTENDED POSITION FED
BACK?
The linear actuator does not have a
direct position feedback function.
extends the tappet depending on the direction of rotation. adjusted manually and can thus be The position can be determined via the stall current of the

02
The linear actuators with spring drive enable automatic unlocked via a cable pull in the event motor, as soon as the tappet is retracted/extended.
resetting (retraction or extension) after the motor is of an emergency.
WHAT IS THE POSITIONING
switched off.
FORCE OF THE LINEAR
ACTUATOR?
The usable positioning force depends
on the voltage, temperature, load and
travel. The worst case is at high temperatures (+80°C) and low

04 07
voltages (9 V/18 V), and is approximately 30 N for most
actuators. The application can be designed based on this
specification. The best case is at low temperatures (-40°C) and
WHAT MUST BE CONSIDERED HOW IS THE LINEAR
higher voltages (15 V/30 V), and is up to 170 N. This force FOR THE LINEAR ACTUATOR ACTUATOR PROTECTED
must be absorbed by the application. Very strong actuators APPLICATION? AGAINST MOTOR
require a counter-load for their safe function; if this is not The tappet may not be subjected to OVERHEATING?
available, a weaker version must be used. any transverse forces, because this
can lead to a defect (blocking transmission) in the actuator. A temperature-dependent resistor
The stroke of the tappet must travel the full distance and must (PTC) is integrated into the motor as
not be mechanically limited by the application, because this thermal overload protection.
can also damage the transmission.
The end-position stability of the retracted/extended positions
is achieved through the short-circuited motor upon successful
triggering.
76 | 77 LINEAR ACTUATOR

LINEAR ACTUATOR
APPLICATION EXAMPLE: PASSENGER VEHICLE

LINEAR ACTUATOR
THE FACTS
The HELLA linear actuator (LA) unlocks the hood via a hook opened by a Bowden
cable. By "releasing" the actuator, the hook is brought back into the closed position
and the hood is locked. The HELLA linear actuator can be used for numerous
customer-specific applications, and can be easily integrated into the vehicle
architecture.

Hood lock Linear actuator with Bowden cable Linear actuator

78 | 79 LINEAR ACTUATOR

LINEAR ACTUATOR
APPLICATION EXAMPLE: AGRICULTURE

LINEAR ACTUATOR
THE FACTS
In the agricultural sector, precision is often particularly important in field work – for
example in the precise dosage of fertilisers and seeds. This is an ideal field of
application for linear actuators which, for example, enable targeted quantity control
through the targeted opening and closing of hoses. Due to various mechanical
interfaces, the linear actuators can be flexibly adapted to different customer
requirements; high-quality mechanical elements ensure the connection of the
actuator with the respective application.

Installation position of the linear actuator Linear actuator

80 | 81 HIGH-FORCE ACTUATOR

ACTUATOR
HIGH-FORCE ACTUATOR

High-force-actuators are used whenever very high

positioning forces (output) need to be controlled
with the least possible mechanical energy (input).
Thanks to universal interfaces (Bowden cable) and
the compact and robust design, they are flexibly
suitable for numerous locking and unlocking as
well as pull-closing applications in the automotive
sector.
82 | 83 HIGH-FORCE ACTUATOR

FAQ

04 WHAT IS THE TORQUE OF

THE HIGH-FORCE-
ACTUATOR?
The high-force-actuator provides a
torque of up to 300 N cm, and is
therefore suitable for applications
that require high forces.

05 HOW IS THE POLARITY

OF THE ELECTRIC MOTOR

03
REVERSED?
An H-bridge can be used to control
WHAT MUST BE the electric motor, which enables
CONSIDERED FOR THE polarity reversal.
HIGH-FORCE-ACTUATOR
APPLICATION?
The actuator may not be mechanically

01
WHAT AREAS OF
APPLICATION CAN THE
HIGH-FORCE-ACTUATOR BE
USED FOR?
The high-force-actuator is particularly
suitable for locking and pull-closing applications where high
forces are required. Examples include large locks, large flaps
and seat release functions.
02 06
limited or restricted by the application. The high impact pulse
(approx. 7 to 8 Nm) can damage the application, the bracket
HOW DOES THE HIGH-FORCE- or Bowden cable.
HOW CAN THE HIGH-FORCE-
ACTUATOR WORK? The customer application must ensure that in the rest ACTUATOR BE UNLOCKED IN
The high-force-actuator is a DC position, there are no loads acting on the actuator in order to AN EMERGENCY?
actuator with rotatory output for avoid damaging the internal limit stop. The high-force-actuator does not
repositioning mechanics between A motor short circuit is necessary during mainspring return. have an emergency unlocking
2 positions. The actuator is operated by applying an electrical The short-circuited motor has a braking effect that protects function.
voltage in both directions of rotation. the internal limit stop. Without this, the dynamism in the
The high-force-actuator with integrated spring enables system can damage the limit stop during the return action,
automatic return once the motor is switched off. which can lead to the device becoming blocked.

07
Any distortion of the housing due to screwing actions must
be avoided.
HOW IS THE RETRACTED/
EXTENDED POSITION FED
BACK?
The high-force-actuator does not
have a direct position feedback. The
position can be determined via the stall current of the motor
once the end position has been reached.
84 | 85 HIGH-FORCE ACTUATOR

HIGH-FORCE ACTUATOR
APPLICATION EXAMPLE: PASSENGER VEHICLE

HIGH-FORCE ACTUATOR
THE FACTS
The HELLA high-force-actuator is particularly suitable for applications that require a
high actuating force, such as the power closing device for the trunk door or seat
release.
The sensor is continuously being developed and can be integrated into customer-
specific applications via various interfaces for Bowden cable couplings.

High-Force Actuator Rear seat release Boot pull-closing aid

86 | 87 SMART UNIVERSAL ROTARY ACTUATOR

ACTUATOR
SMART UNIVERSAL ROTARY ACTUATOR

The robust HELLA Smart Universal Rotary

Actuators (URA) are suitable for a wide range of
applications, even under harsh operating
conditions, such as seed dosing in the agricultural
sector and for controlling supply/exhaust air flaps.
The integrated CIPOS® position sensor directly on
the output gear and the self-locking transmission
ensure maximum precision in the control system.
88 | 89 SMART UNIVERSAL ROTARY ACTUATOR

FAQ

01 WHAT AREAS OF
APPLICATION CAN
THE SMART UNIVERSAL
ROTARY ACTUATOR (URA)
BE USED FOR?
05 HOW DO THE ACTUATOR AND
THE VEHICLE COMMUNICATE
WITH EACH OTHER?
They can communicate with the help

08
The URA can be used in a broad range of applications of a pulse width modulated signal or
involving harsh environmental conditions. High torque and via a LIN interface. Furthermore, the URA is equipped with
CIPOS® technology enable precise and reliable position automatic communication type detection (PWM or LIN) as
WHAT IS THE WORKING
control. Examples include of this include seed dosing/ well as automatic baud rate detection for LIN. ANGLE RANGE OF THE
isolation and the control of supply/exhaust air flaps. SMART URA?
Thanks to its design, the URA can be
flexibly adjusted in its working range.
Up to 8 revolutions (8 x 360°) are

03
possible.

WHAT TEMPERATURE RANGE

CAN THE SMART URAS BE
USED IN?

06
The operating temperature of the
actuator is in the range of -40 °C to
DOES THE SMART URA HAVE
85 °C. Due to the integrated protection electronics, the URA is A CAN INTERFACE?

02
also protected against overheating. No, the URA can only be controlled

09
via PWM or LIN.
HOW DOES THE
SMART URA WORK? WHAT IS THE DEGREE OF
The URA monitors the position of the ACCURACY OF THE SMART
output gear wheel and the integrated URA?
electronics continually calculate the The "True Power On" function enables
position with the aid of an ASIC. The actuator offers the "True absolute measurement of angles up

04
Power On" function for angles less than 180°, i.e. it enables to 160° (including all tolerances). In addition, the precise
direct commissioning without calibration. position can be determined with the aid of a calibration
WHAT IS THE SERVICE LIFE

07
During operation, the actuator executes controlled routine. If a calibration routine is not possible, the position is
movements to the programmable "soft stops". The current OF A SMART URA? determined on the basis of the desired value sent by the
consumption required to hold a defined position is low due to The HELLA service life test is based
WHAT IS THE TORQUE OF THE control unit.
the self-blocking transmission (< 25 mA). on the ISO 16750-3 standard and SMART URA?
covers 250,000 full strokes The minimum torque is 60 N-cm. The accuracy of the actuator between the current position and
(90° strokes) at a defined torque and temperature profile. Depending on the service life the transmitted desired value is ±3.6°.
requirements, the torque can be
increased up to a maximum of
200 N-cm.
90 | 91 SMART UNIVERSAL ROTARY ACTUATOR

FAQ

10 HOW DO I ADAPT THE SMART

URA TO MY APPLICATION?
The URA is calibrated to the applied

13
system through a teach-in routine.
This process can be triggered either
via a PWM signal or a LIN command. The URA cannot be
IS ERROR DETECTION
interrupted during this routine. INTEGRATED INTO THE
ACTUATOR?
The URA does not have an internal
error memory. Different errors are
detected, to which the URA can react
differently.

11 HOW IS THE CURRENT

POSITION DETERMINED?
The current position is measured
via the integrated EMC-resistant
Contactless Inductive Position Sensor.

14
CIPOS® technology is non-contact and
is therefore a wear-free process.
HOW CAN ERRORS IN A PWM
SIGNAL BE DETECTED AND
DIFFERENTIATED?
If an error occurs, the PWM input
signal is grounded for a defined time

12
(set to low). A distinction can be made between the error
groups based on the amount of time that the PWM signal is
HOW DOES THE URA set to low.
BEHAVE IN TERMS OF
ELECTROMAGNETIC
COMPATIBILITY (EMC)?
The electronics work in the range of
approximately 3.5 MHz. Other devices that emit interference in
this range could affect the URA.
92 | 93 SMART UNIVERSAL ROTARY ACTUATOR

SMART UNIVERSAL
ROTARY ACTUATOR
APPLICATION EXAMPLE: AGRICULTURE

SMART UNIVERSAL ROTARY

ACTUATOR
THE FACTS
The Universal Rotary Actuator (URA) from HELLA enables a broad range of
applications even under harsh environmental conditions. In the agricultural sector,
the URA is used, for example, in seed dosing/isolation. CIPOS® technology and a
high torque enable precise and reliable position control. A flexible working angle
range and the "True Power" function up to an angle of 180° enable particularly
precise applications.

The Smart Universal Rotary Actuator is used here to isolate the seed Smart Universal Rotary Actuator (URA)
94 | 95 ROCKER SWITCH

SWITCH
ROCKER SWITCH

Rocker switches have many different functions

and are indispensable in any vehicle these days.
The rocker switch program, proven over decades
of everyday use and continuously developed by
HELLA, enables great flexibility in implementing
specific customer requirements and features a
timeless design. In addition to a large selection of
switches and functions, we offer individualised
and abrasion-resistant laser marking along with
the standard characters. Customers can thus
determine their preferred characters themselves.
Always included: high HELLA quality.
96 | 97 ROCKER SWITCH
FAQ
01 WHAT IS A ROCKER SWITCH?
The rocker switch range consists of a
total of four different series. The
switches are modular and can be
individually configured to suit
customer requirements – starting with a single application
right through to complete vehicle equipment.
02
WHAT IS THE DIFFERENCE
BETWEEN THE 3100
AND 4100 SERIES?
Due to a variety of customer
requirements, two new, different series have been developed:
Series 3100 for robust and waterproof applications and series
4100 for indoor applications and the safe switching of low
currents.
03 HOW ARE THE SERIES
CONFIGURED?
With the help of the HELLA rocker
switch configurator, you can put
together your individual switches
simply and clearly.
www.hella.com/switch
05 HOW IS THE ROCKER SWITCH
MOUNTED?
The switches are snapped onto
a specified installation opening
either directly or by means of an
09 WHAT ACCESSORIES ARE
AVAILABLE?
In addition to individual frames,
modular intermediate and end pieces
that can be combined together are
installation frame. also available, meaning that switch
rows can be created. Matching mating connectors, indicator
lights and disassembly tools round off the range of
accessories.
06 WHAT DESIGNS ARE
AVAILABLE?
04
ON/OFF switches (0-I), changeover
WHICH CONFIGURATIONS switches (0-I-II, I-0-II), hazard
ARE POSSIBLE?
10
warning switches, disable switches,
First select the switch series that interlocking switches.
suits your requirements. Now you
WHAT IS THE
can define the operating voltage; "INDICATOR LIGHT"
choose from a variety of switching functions and symbol SWITCH TYPE?
07
combinations. With just a few clicks you can create the switch In an identical design, the indicator
required for your application. You can then choose from a light provides additional information
wide range of accessories as an option.
WHY CAN I on control and warning devices in the
CHOOSE BETWEEN vehicle, e.g. an applied handbrake.
Save the selection in a watch list or request the configured DIFFERENT SWITCHING
switches directly online. It cannot be easier! If your desired CIRCUITS?
requirements are not included, there is also the possibility Certain applications require the
of a personal request. simultaneous switching of different circuits. Therefore, the
choice is between one and two switching circuits.
11 WHAT DO THE TERMS
ORIENTATION LIGHTING
08
AND FUNCTIONAL
WHAT LIGHTING COLOURS LIGHTING MEAN?
ARE AVAILABLE? Orientation lighting is used to
Both series are equipped as standard locate the switch at night. The function check is used for
with green orientation lighting and confirming the switched-on function.
red functional lighting.
98 | 99 ROCKER SWITCH

ROCKER SWITCH
APPLICATION EXAMPLE: MOBILE CRANE

ROCKER SWITCH
THE FACTS
The HELLA rocker switch range, which boasts four series, offers the right
configuration for every application thanks to its wide range of functions and
countless symbols. Safe switching is guaranteed, even under difficult conditions.
This is ensured by means of precise feedback, unambiguous symbols and the
integrated orientation and functional lighting. A disable mode is also available
as an option.

Series 3100 Series 4100 Series 4570 and 7832 Application example series 4100
100 | 101 ONLINE TOOLS

THE NEW ROCKER SWITCH CONFIGURATOR

The switch for your requirements in just a few steps! It is now even
easier and more straightforward to put your individual switches
together thanks to the new HELLA rocker switch configurator.
With just a few clicks, choose from various criteria and switch
accessories for the 3100 or 4100 series – it has never been easier!
You don't have to miss out on our proven basic range, the 4570/7832
series, either, thanks to the range overview – including the article
number, of course, for your next order.
www.hella.com/switch

THE ELECTRONICS TOOL FOR

SPECIAL ORIGINAL EQUIPMENT
Our electronics tool informs you quickly and clearly of which
electronic products HELLA offers for special original
equipment.
First, select an appropriate vehicle or area of application
(drive train or cab). After selecting the appropriate product via
mouse click, you will receive further information as well as
PDFs with important information and technical data for
downloading. In addition, the tool provides clear
animations showing how the products work.

HELLA YOUTUBE CHANNEL

In addition to informative product and application videos, you will
also find many helpful tips and advice on our comprehensive HELLA
product range on the HELLA YouTube channel.
www.youtube.com/HELLAKonzern
HELLA GmbH & Co. KGaA
Rixbecker Straße 75
59552 Lippstadt /Germany
Tel. + 49  2941  38 - 0
Fax + 49  2941  38 - 71 33
info@hella.com
www.hella.com

© HELLA GmbH & Co. KGaA, Lippstadt

9Z2 999 141-713 J01516/FR/11.18/0.8
Printed in Germany
Subject to technical and price modifications.

www.hella.com/soe-electronics